Process and apparatus for making roofing elements



T. ROBINSON PROCESS AND APPARATUS FGR MAKING ROOFING ELEMENTS Filed June 11, 1925 QR la ATTORNEYS i Patented Aug. 30, 1927.

UNITED STATES THOMAS ROBINSON, OF NEW YORK, N. Y.

PROCESS AND APPARATUS FOR MAKING ROOFING ELEMENTS.

Application filed June 11, 1925.

This invention relates to a method of and apparatus for the manufacture of a novel type of roofing element of the kind known as prepared roofing, and disclosed in my two co-pending applications Ser. No. 22,057, filed April 10, 1925, and Ser. No. 33,976. filed June 1. 1925.

The prepared roofing disclosed in these applications affords many advantages over the prepared roofings as heretofore produced, by reason of the fact that the new type of rooting is much cheaper, more rigid, has a better appearance when laid, and has greater durability. The new roofing consists of a body made of a hardened plastic substance, preferably one consisting of comminuted inert material, and a cementitious binder. This body has the form of the finished element, and may be either tapered or of uniform cross-section and of a size similar to a single or a multi-unit shingle. In the latter instance, the element has the usual strip form and is provided with cut-out indentations along one margin which define a plurality of tabs, each of which has the appearance of a single shingle when these strips are laid in courses in the usual maimer. The body is encased within a jacket made of a sheeted material, preferably a paper 0 product which is impregnated with a waterresistant composition, such as asphalt. The sheet encases both ends and the two opposite faces of the body, leaving the lateral edges exposed, and after the sheet has been applied the element is coated with a waterproofing material, such as asphalt, and is then given a wear surface of a suitable material, such as crushed slate.

The present invention is intended to provide a method and apparatus by which this product may be made, in large quantities, of uniform quality and at a low labor cost, and according to the invention, the enclosing jacket or sheet is doubled upon itself to provide a fold, and while maintained in folded relation and supported so as to be relieved from strain, is given a slow longitudinal movement. In the course of this movement, the material which forms the body is continuously introduced into the fold, the filled sheet is then moved beyond the station at which the filler is introduced, and is successively subjected to the other operations involved in producing the final product. At

the completion of the process the strip is cut Serial No. 36,312.

into selected lengths which form the individual roofing elements, and these lengths are ready for immediate use.

For a better understanding of the invention, reference will be made to the accompanying drawings, in which Fig. l is a side elevation of the ap aratus by which the method is practiced, t is apparatus being shown largely in conventional form,

Fig. 2 is a top plan view of the apparatus shown in Fig. 1,

Figs. 3, 4, and 5 are sectional views on the lines 3-3, 44, and 55, respectively of Fig. 1,

Fig. 6 is a sectional view on the lines 6-6 of Figs. 1 and 7,

Fig. 7 is a face view of a supporting member,

Fig. 8 is a plan view of this supporting member, and

Figs. 9 and 10 are sectional views through the folded sheet material showing the relation of the plies in two different elements.

Referring to these drawings, and particularly to Fig. 1, the supply of sheeted material is designated 12 and this supply may take the form of a roll of the material of indefinite length. Thissheet, as previously pointed out, may be of numerous materials, but is preferably made of asphalt impregnated paper, since this is satisfactory and 'of lowcost. Passing from the supply, the

material is moved past a station designated 13, at which a folding operation takes place. Ordinarily, for the simpler type of shingle, there is provided at this station a suitable guide which bears down upon the face of the sheet so as to fold it lengthwise into two plies, such as 14 and 15, as shown in Fig. 9. These two plies diverge from the line of folding 16 and are spaced .apart in accordance with the taper that the finished element is to have from front to rear.

Passing from the station at which the folding operation takes place, the sheet enters a V-shaped trough or guide 17 of metal, which is steam jacketed, and in general has a cross-sectional appearance such as is illustrated in Fig. 6. Suitable guides may be provided, if necessary, for maintaining the sheet with the two splies in proper folded relation within the guide 17. The sheet moves along the guide 17 and passes into a V-shaped channel 18 in a wheel 19. The

wheel is hollow so that steam may be introduced into it in any desired manner, and thus keep it at the desired temperature. The wheel is driven from any convenient source of power and serves in part to draw the sheet from the supply and propel it past the different stations at which various operations take place.

Disposed above the wheel 19 is a feeding device 20, which may take the form of a hopper in which is placed the plastic filling material which is to be introduced into the fold in the sheet. The filling material employed is preferably a mixture of asphalt and asbestos sand, although other comminuted inert materials, together with a plastic binder, may also be employed. The feeding device is provided with a discharge aperture placed so that material will pass through this aperture into the fold of the sheet, and if desired, suitable feeding mechanism of any appropriate form may be placed in the hopper so as to insure that a continuous supply of the material is passed into the sheet."

Passing from the wheel 19, the filled sheet next passes into a V-shaped channel in the wheel 21, similar to the wheel 19. This wheel is also jacketed, and may be kept at the desired temperature by steam or other heating medium. As shown in Fig. 3, the edges 22 of the plies 14 and 15, project a slight distance above the rim of the wheel, and there is mounted in any convenient man- 'ner above the wheel, so as to extend between these plies, a tamping or pressing wheel 23. This wheel bears against the surface of the mass of filler which has been introduced into the fold of the sheet, and acts to pagk or tamp this filler tightly so that there will be no voids in the mass. Between the wheels 19 and 21, there is a stationary support 24, shown more clearly in Fig. 7. This support is mounted in any convenient manner, as by means of a standard extending to the floor, and forms a V-shaped channel through which the filled sheet moves. The sides 25 of the support on either side of the channel, serve to maintain the plies of the sheet in the de sired relation and also to relieve the sheet from the weight of the filler. A

Beyond the wheel 21, the filled sheet passes into the channel of a third wheel 26, which has a construction similar to the wheel 21, and is similarly jacketed, so that it may be maintained at the desired temperature. Above the axis of the whezfl 26 is placed a ressin roller 27 mounte in any conveniiant ma nnmhis roller serves to bear against the projecting edges 22 of the plies 14 and 15 and turn these edges inwardly to the position indicated at 28 1n Fig. 4. Between the wheels 21 and 26, is a support 24. Beyond the wheel 26, the material passes through another support 24, and thence into a channel in the wheel 29 of a construction similar to the wheel 26. Above this wheel is placed a roller 30, which bears doWn on the exposed edges 22 of the plies and forces these edges into the overlapped position shown in Fig. 5 at 31. At this stage in the operation it will be seen that the sheet which has been folded into a V-shape, has been filled with the plastic filling material which has been tamped firmly together so as to prevent the formation of voids, and the exposed edges of the sheet have been overlapped to close the open end.

When the filled sheet thus produced is to be utilized in the production of multi-unit strips, the next step in the process is the formation of the cutouts, and for this purpose cutting devices indicated conventionally at 32 are provided. These devices may consist of rolls placed in an inclined position so as to bear against either face of the sheet, one of these rolls being provided with a knife member 33, while the other has a recess 34, into which the knife enters. These rolls are driven in any convenient manner, and at each revolution of the rolls the knife member acts to cut out a narrow strip of the sheet at its butt mi. As shown in Fig. 1, the knife 33 extends only a part of the distance transversely of the sheet, and the cutouts thus serve to define a plurality of tabs, each of which has a width corresponding to the width of the average single unit shingle. If the sheet is to be used in the production of elements which do not have the cutouts, then the cutting devices 32 are omitted.

Passing beyond these cutting devices, the sheet is next subjected to a coating operation, and this may be conveniently carried on by passing the sheet between rolls 35 which rotate into a vat 36 of the coating material. Preferably the coating material is of a water-proofing compound, such as asphalt which has a melting point suflicient to withstand solar heat, and the vat is provided with heating devices in order to maintain the asphalt in a fluent condition. The coating wheels 35 serve to apply the asphalt on either face of the sheet, and the thick end of the filled sheet may be coated by means of a roller 37, bearing against this thick end and supplied with coating material in any convenient manner. In addition to the coating rolls 35 and 37, rolls 38 may also be employed, mounted on inclined vertical axes and bearin against either face of the sheet. These rol s are employed for the purpose of insuring that the coating material is spread evenly throughout all areas of the sheet. Passing beyond the last coating rolls, the sheet is now r r cutting intpWEg in the event that a p ainc ur ace roduct is to be produced, but ordinarily a wear surface of crushed slate or other similar material is employed. Also, it is desirable to apply tale to the surface of the water-proof coating, in order to overcome the tackiness of the latter. The application of the wear surface and the talc occurs at the station designated 39, the slate being applied to one surface and the end of the filled sheet, while the talc is applied to the other surface. Any suitable or convenient device may be employed for the purpose, and the material is first distributed over the face of the sheet and then the sheet subjected to pressure between rolls bearing on either face of the sheet at the station 39.

Beyond the point at which the application of the wear surface and the talc takes place, the sheet is passed through a channel in a roll 40, similar to the rolls previously described. This roll is jacketed and is water-cooled, so that it serves to absorb heat from the filler and the coating, thus hastening the setting of the plastic material used in the coating and filler. Beyond the cooling roll, the sheet is cut into selected lengths, and this operation may be carried on by means of cutting devices 41 and, 42,

similar to the rolls 32. The roll 42 is provided with a knife and the roll has a recess 44 for the knife. As these rolls are driven from any convenient source of power, at each rotation the knife cuts the strip transversely, and by a selection of rolls of the proper diameter, units of any desired length may be cut from the strip.

It will thus be seen that according to this process, the jacket sheet serves as a mold in which the body of the element is formed and the sheet is supported at all times during its movementso that the several operations involved in the manufacture of the finished product may be carried on without damaging the sheet. Ordinarily, the sheet is of relatively thin material, and by providing such support, not only is it possible to make use of the sheet as a mold, but also the support serves to define the cross-sectional form of the finished product. As here shown, the process is one in which units are produced which have a gradually increasing thickness from the rear to the forward edge, as they will ordinarily be used. If it should be desired, however, to produce an element having a uniform thickness, then wheels such as 19 would be employed having a straight-sided channel, the width of which corresponds to the outside thickness of the finished product.

In the event that an element is to be produced in which one of the. plies is provided with a transverse fold, such as is indicated generally at 45, this fold serving a number of purposes, pointed out in my co-pending application, Serial Number 33,976, filed June 1, 1925, then this fold is formed in the sheet at the station 13. As the sheet is drawn from the supply it is doubled upon itself lengthwise, and then one of the plies is further folded upon itself to provide the lap 45. Since the sheet is moving away from the supply, the production of these folds is easily carried on by the use of suitable finger guides which may be mounted at the station 13, in accordance with the usual practice.

It will also be seen that I have provided an inexpensive process and apparatus for the production of roofing elements which are of cheap construction and which may be produced in large quantities and at a low labor cost. Very little attention is required in carrying on the process, all of the parts being simple in operation. The materials employed in the manufacture of the new element consist of the sheet material, the filler, the coating substance, and the material used for producing the wear surface, and supplies of these may readily be replenished, from time to time as may be necessary. The process, further, is a progressive process in which the materials are utilized one after another, as required, and at the end of the process the finished elements are discharged and may be removed and stored or otherwise disposed of.

I claim:

1. A method of making building material, which comprises moving a web of sheet material len thwise and, while the web is in motion, olding it longitudinally along a line and supporting the plies of the Web in opposed relation and relatively close together to provide a narrow trough, introducing a plastic filling material into the said trough, applying pressure on the filling material within the trough to compact it, and cutting the filled web into selected lengths.

2. A method of making roofing which comprises moving a web of sheet material lengthwise and, while the web is in motion, folding it longitudinally along a line and supporting the plies in vertical opposed positions, introducing a filling material into the fold, cutting narrow vertical strips from th upper thick edge of the filled sheet to define a succession of tabs along that edge, and cutting the filled sheet into selected len he.

3. A method of making roofing which comprises moving a web of sheet material lengthwise and. while the Web is in motion, folding it longitudinally along a line, supporting the folded web with the fold at the bottom and the plies extending therefrom in opposed relation and a short distance apart filling material into the fold, turning the edges of the plies inwardly to cover the filling material, and cutting the filled web into selected lengths.

4. A method of making building material, which comprises moving a longitudinally folded sheet lengthwise while supporting its plies in opposed relation and close together, whereby a narrow trough is formed, introducing a filling material into the fold to fill the said trough, applying pressure on the filling material within the fold to compact it, and cutting the filled web into selected lengths.

5. A method of making buildin material which comprises moving a longitudinally folded sheet lengthwise while supporting the plies of the sheet on either side of the fold in substantially verticalposition and in opposed relation a short distance apart, introducing a plastic filling material into the fold, applying pressure to the filling material within the fold to compact the latter, folding the edges of the plies one upon the other to cover the fillin material within the fold, and cutting th filled sheet into selected lengths.

6. A method of making roofing which comprises moving a web of sheet material lengthwise, and, while the web is in motion, folding it longitudinally to provide two plies, folding one of these plies upon itself to provide a band of increased thickness, introducing a filling material between the plies, and cutting the filled web into selected lengths.

7. Apparatus for making roofing which comprises the combination of means for drawing sheet material continuously from a supply, means for folding the sheet material lengthwise and turning the folds vertically, means for supporting the folded sheet with its plies diverging from the line of folding, means for introducing filling material between the plies of the sheet, cutting devices for cutting vertical strips from the upper edge of the filled sheet to define a succession of tabs, and cutting devices for'cutting the filled sheet into selected lengths.

8. Apparatus for making roofing which comprises the combination of a supply of sheet material, means for folding the sheet material lengthwise, a p urality of rotary devices adapted to receive the folded sheet and advance it longitudinally, means for introducing a filling material between the plies 0f the sheet, means for applying pressure to the filling material lying within the fold to compact the latter, cuttin devices for cutting narrow strips from t e filled sheet to define a succession of tabs along one edge, and cutting devices for cutting the filled sheet into selected lengths.

9. Apparatus for making roofing which comprises the combination of a supply of sheet material, mea or folding the sheet material lengthwise along a line to provide a narrow substantially vertical trough defined by the web on either side of the line of folding, a plurality of rotary devices adapted to receive the folded sheet and advance it longitudinally, means for introducing a filling material between the plies of the sheet, a pressing roller acting on the filling material within the plies to compact the latter, and cutting devices for cutting the filled sheet into selected lengths.

10. Apparatus. for making roofing which comprises the combination of a supply of sheet material, means for folding the sheet material lengthwise, a plurality of rotary devices adapted to receive the folded sheet and advance it longitudinally, means for introducing a filling material between the plies of the sheet, means for coating the filled sheet, and cutting devices for cutting the filled sheet into selected lengths.

11. Apparatus for making roofing which cgmprises the combination of a supply of s eet material, means fo foldin the sheet material lengthwise, a plurahty of rotary devices adapted to receive the folded sheet and advance it longitudinally, means for introducing a filling material between the plies of the sheet, means for coating the filled sheet, means for applying a wear surface to the coated sheet and cutting devices. for cutting the filled sheet into selected lengths.

12. Apparatus for making roofing which comprises means for drawing sheet material continuously from a supply, folding means for folding the sheet material engt wise along a line, means for supporting the plies of the sheet substantially vertical, means for introducing a filling material between the plies of the sheet, rollers for folding the edges of both plies inwardly over the mass of filling material, and cutting devices for cutting the filled web into selected lengths.

In testimony whereof I afiix mv signature.

THOMAS ROBINSON. 

